Derbi GPR 125 R

1This manual has been produced by Nacional Motor, S.A.U. for use by DERBI dealer and sub-agency works-hops. It is assumed that those using this publication for training purposes and for repairing DERBI machines have a basic knowledge of mechanics and of the methods inherent in the technique of vehicle repair. Signifi-cant variations in the characteristics of the machines or in the specific repair operations will be communicated by means of updates to this manual.

Completely satisfactory work cannot however be carried out without the availability of suitable facilities and tools, which is why we ask you to consult the pages of this manual referring to special tools and imple-ments.

Particularly important items of information in this manual are distinguished by the following annotations:

N.B. INDICATES A NOTE GIVING KEY INFORMATION, MAKING THE PROCEDURE EASIER AND CLEARER.

ATTENTION INDICATES SPECIFIC PROCEDURES THAT MUST BE FOLLOWED TO PREVENT DAMAGE TO THE MACHINE.

WARNINGINDICATES SPECIFIC PROCEDURES THAT MUST BE FOLLOWED TO AVOID POSSIBLE INJURIES TO THE PERSON REPAIRING THE MACHINE.

NACIONAL MOTOR, S.A.U.

3GENERAL INFORMATION

MAINTENANCE REGULATIONS

GENERAL TECHNICAL DATA

MAINTENANCE SPECIFICATIONS

TIGHTENING TORQUES

CHASSIS SPECIFICATIONS

ELECTRICAL SYSTEM SPECIFICATIONS

GENERAL TIGHTENING TORQUE SPECIFICATIONS

PERIODICAL INSPECTIONS AND ADJUSTMENTS

SEAT, FAIRING AND FUEL TANK

ENGINE

CHASSIS

ELECTRICAL SYSTEM

ENGINE INSPECTION

DISMANTLING THE ENGINE

INSPECTION AND REPAIR

REASSEMBLING THE ENGINE AND MAKING ADJUSTMENTS

CHASSIS FRONT WHEEL AND BRAKES

REAR WHEEL AND BRAKES

TRANSMISSION

FORKS

HANDLEBARS

SHOCK ABSORBER AND SWINGING ARM

ELECTRICAL SYSTEM

INSPECTING THE SWITCHES

TROUBLESHOOTING

Page 4Page 5Page 6Page 11Page 15Page 17Page 19Page 21Page 24Page 26Page 28Page 35Page 40Page 44Page 45Page 56Page 65

Page 96Page 106Page 116Page 119Page 125Page 129Page 131Page 135Page 136

4REGULATIONS

This section describes the machines general safety and maintenance work rules.

SAFETY REGULATIONS

In the event of having to carry out work on the engine while this is running, ensure that the area is well ven-tilated, where possible using extractor fans. Never leave engines running in closed spaces. Exhaust gases are poisonous.

Petrol is extremely inflammable and in certain conditions may explode. Smoking must not be allowed in the work area, nor should there be naked flames or sparks.


- Use genuine DERBI spare parts and lubricants recommended by the Manufacturer. Non-genuine or unau-thorised parts may damage the engine.

- Always use new gaskets and oil seals during re-assembly.

- After dismantling, clean the components with solvents that are non-inflammable or with a high flammability point. Lubricate all working surfaces before re-assembling, excluding tapered joints.

- After re-assembly, check that all components have been correctly fitted and that they are functioning per-fectly.

- For dismantling, checking and re-assembly operations, use only tools with metric measurements. Metric screws, nuts and bolts are not interchangeable with imperial measurement joining devices. Using unsuitable tools and joining devices may damage the engine.

- In the case of work on the engine involving the electrical circuitry, check that electrical connections have been correctly fitted.

REGULATIONS

SAFETY REGULATIONS


5Use genuine DERBI spare parts and lubricants recommen-ded by the Manufacturer. Non-genuine or unauthorised par-ts may damage the machine.

Only use the specific tools intended for this machine.During re-assembly, always use new seals, gaskets, piston rings and grommets.

After dismantling, clean the components with solvents that are non-inflammable or that have a high flammability point. Grease all working surfaces before assembling, excluding tapered joints.

After assembly, check that all components have been correc-tly fitted and that they are functioning perfectly.

For dismantling, checking and re-assembly operations, use only tools with metric measurements. Metric screws, nuts and bolts are not interchangeable with imperial measure-ment joining devices. Using unsuitable tools and joining de-vices may damage the machine.

In the case of work on the machines electrical circuitry, check that electrical connections have been correctly fitted, especially the earth connections.

VEHICLE IDENTIFICATIONVEHICLE IDENTIFICATION

VEHICLE

GPR 125 Racing

CHASSIS CODE ENGINE CODE

E1 19ExxxxxxVTHGS1A1A?Hxxxxxx

6RACING 125 GENERAL TECHNICAL DATA

Engine

Diameter x stroke

Cylinder capacity

Carburettor

Cooling

Starting

RACING 125 GENERAL TECHNICAL DATA

Compression ratio

Maximum power

Fuel

Greasing system

Ignition

Spark plug

Primary transmission

Clutch

Front suspension

Rear suspension

Gears

Single cylinder 2-stroke EURO 2

56,0 x 50,7 mm

124,9 cm3

Mikuni TM 28-92

Liquid

Electric

12,5 : 1

11 kW (14.9 HP) / 8.000

Lead-free petrol

Wet crankcase

Ignition D.I.U-

NGK BR8ES

Gears

Multi-disk

40 mm hydraulic fork. 110 mm travel

Single shock absorber. 14mm rod. 110 mm travel

6 speed

Tyres 140/70 x 17

Front disk brake

Rear disk brake

Battery

Distance between axles

Height

Length

Width

Fuel tank

300 mm hydraulic disk

180 mm hydraulic disk

12 V 4 Ah

1.355 mm

1.160 mm

2.024 mm

720 mm

13 L.

7PREPARATION FOR REMOVAL AND DISMANTLING

1. Remove all the dirt, grime, dust and other foreign material before removing and dismantling.

2. Use proper cleaning tools and equipment.

See SPECIAL TOOLS.

3. On dismantling the motorcycle, always keep paired par-ts together. This includes gears, cylinders, pistons and other parts submitted to natural wear in pairs. Paired parts must always be reassembled or replaced together.

4. While dismantling the motorcycle, clean all the parts and lay them out on trays in the order dismantled. This speeds up reassembly and ensures the correct fitting of all the parts.

5. Keep all parts away from any contact with fire.

PREPARATION FOR REMOVAL AND DISMANTLING

8SPARE PARTS

1. Use only genuine DERBI spare parts. For all lubrication tasks use oils and greases recommended by DERBI. Other makes may seem similar in their function and appearance, but are inferior in quality.

SEALS, RETAINING RINGS AND O-RINGS1. Replace all seals, retaining rings and O-rings when servi-cing the engine.All surfaces receiving seals, retaining ring edges and O-rings must be cleaned.

2. Apply oil to all paired parts and bearings during reassem-bly. Apply grease to the retaining ring edges.

TAB WASHERS/SPACERS AND SPLIT PINS1. After removing them, renew all tab/spacer washers (1) and split pins. Bend the tabs to fit the flat surfaces of the bolt or nut once they have been tightened to the specified torque.

BEARINGS AND RETAINING RINGS

1. Fit bearings and retaining rings in such a way that the ma-nufacturers marks remain visible. On fitting retaining rings, applying a thin film of light lithium soap based grease to their edges. Where required, apply oil generously when fit-ting bearings.

WARNINGDO NOT USE COMPRESSED AIR TO DRY BEARINGS. THIS WILL DAMAGE TO THE BEARING SURFACES.

S S

SEALS, RETAINING RINGS AND O RINGS

TAB WASHERS/SPACERS AND SPLIT PINS

GS G GS

9LOCKING RINGS

1. Examine all the locking rings carefully before fitting. Always replace the gudgeon pin circlips after every use. Re-place distorted locking rings. On fitting a locking ring (1), ensure that the sharp edge (2) is on the opposite side to the force (3) to be applied to it.

See the figure on the side, (4) Axle.

SPECIAL TOOLS

The following special tools are needed for assembly and for complete and exact adjustments. Only use the proper special tools; thereby avoiding damage caused by the use of unsui-table tools or improvised techniques.

1.00M12501258

Gudgeon pin extractor.

This tool is used for dismantling the gudgeon pin.

00M12501259

Magneto flywheel extractor.

This tool is used for dismantling the magneto flywheel.

LOCKING RINGS

SPECIAL TOOLS

10

3. 00M12501260

Clutch holder.

This tool is used to hold the clutch assembly when fitting or dismantling its axle nut.

4. 00M12501261

Crankcase separator.

This tool is used to separate the crankshaft from the case.

4. 00H05100181

40 mm fork seal inserting tool

This tool is used for inserting the seals into the forks, as des-cribed in the corresponding section.

11

GENERAL SPECIFICATIONSGENERAL SPECIFICATIONS

BASIC WEIGHT With oil and full fuel tank

AIR FILTER

FUEL Type Fuel tank capacity Reserve volume

Wet-type element

131 kg

TYPE OF FLUID Engine oil

AGIP CITY 2-stroke API SJ DONUT + JASO MA - PART SYNTHETIC oil, SAE Viscosity: SAE 10W30 or higher

OIL CAPACITY Engine oil. Regular oil change. Total capacity

0,75 L.0,8 L.

Lead free petrol (95 octane or higher)12 L.2 L.

MODEL GPR 125 Racing

CARBURETTOR Type Manufacturer

TM 28-92/1 MIKUNI

SPARK PLUG Type / Manufacturer Gap between the electrodes

NGK BR8ES 0.7 mm.

CLUTCH TYPECLUTCH TYPE Wet, multi-disk.

TRANSMISSION Primary reduction system Primary reduction ratio Secondary reduction system Secondary reduction ratio Type of transmission Operation Gear ratio 1 2 3 4 5 6

Helicoidal gears 71/22 (3.227) Transmission chain57/16 (3.563) Constant gearing, 6 speed With the left foot

34/12 (2.883)30/16 (1.875)24/17 (1.412)24/21 (1.143)22/23 (0.957)18/22 (0.818)

CHASSIS Frame type Caster angle Trail

Delta Box 26.4109 mm.

12


NEUMTICOSTYRESSize Front Rear

Tubeless

110/80 17 140/70 17

TYRE PRESSURES (COLD)Rider only Front RearRider and passenger Front Rear

170 kPa (1,7 kg/cm2)190 kPa (1,9 kg/cm2)

190 kPa (1,9 kg/cm2)210 kPa (2,1 kg/cm2)

FRENOFront brake Type OperationFront brake Type Operation

300 mm disk. VENTILATEDWith the right hand

180 mm disk. VENTILATEDWith the right foot

SUSPENSION Front suspension Rear suspension

Hydraulic forkSwnging arm + hydraulic shock absorber

SUSPENSION TRAVEL Front Rear

110 mm110 mm

ELECTRICAL SYSTEM Ignition system Charging system Battery type Battery capacity

DIUMagneto flywheel Yuasa MF YTX5L-BS12v 4Ah

BULB VOLTAGE AND WATTAGE PER QUANTITY

Headlight

Frontt side-lightRear side/brake lightFront turn indicatorsRear turn indicators

12v 35W dip H1112v 35W main beam H1112v 2.3W12v 2,3W/16W12v 10Wx212v 2.3Wx2

INDICATOR LIGHTSWater temperature indicatorOil indicatorFuel indicatorMain beam indicatorTurn indicators pilot light

LEDLEDLEDLEDLED

13

ENGINE SPECIFICATIONSENGINE SPECIFICATIONS

CYLINDER HEAD

* The lines indicate measurement at a right angle

CYLINDER Diameter 56,00 ~ 56,02 mm


Conicity limit

Ovality limit

0,05 mm

0,01 mm

PISTON Cylinder-piston play Diameter of piston D

Measurement point H Piston off-set

0.045 0.050 mm

55.950 55.955 mm

10 mm0,5 mm

PISTON RINGS Top ring: Type Dimensions (BxT) Top ring (ignition) Bottom ring Gap between points (fitted) Top ring Bottom ring Side play (fitted) Top ring Bottom ring

Keystone

1.2 x 2.4 mm1.2 x 1.89 mm

0.300 0.450 mm0.300 0.450 mm

0.020 0.060 mm0.035 0.070 mm

T

B

CRANKSHAFT

Width A Connecting rod bottom play D < Connecting rod top play limit F>

57.90 57.95 mm

0.2 0.7 mm

14


CLUTCH Thickness of friction disks Quantity Thickness of the separators Quantity Free length of clutch spring Quantity Minimum length Clutch freeing method Actioning rod warp limit

2.9 3.1 mm7 parts2.7 mm1.05 1.35 mm6 parts0.05 mm34.5 mm5 parts32 mmInternal by lever system

GEAR SELECTOR Type Selector and guide bar

CARBURETTORTypeID markMain jetMain pneumatic jetJet needleNeedle jetPilot outlet Pilot jetBypass1 Pilot screw (turns)Valve seat sizeChoke jet 1Choke jet 2Float heightChamber levelEngine idle speed

TM 28-92/11 DO#2100.75J40 2Q2M (#939)0.6#17.51.62.8#40#6015.5 16.5 mm1.5 2.5 mm1250 1450 rpm

LUBRICATION SYSTEMColour codeMinimum run Maximum runMinimum output Maximum outputPulley adjustment mark

Dark blue0.15 0.20 mm1.85 2.05 mm0.38 0.50 cm34.65 5.15 cm3Self-adjusting

REED VALVEValve thicknessStop plate heighValve bend limit

0.5 mm8.8 mm0.5 mm

15

PARTS TO BE TIGHTENEDTIGHTENING TORQUE

m.KgNmOBSERVATIONS

Spark plug

Cylinder LOCTITE bolt securing adhesive

Cylinder head Cap nuts

Stud bolt

Nut

ENGINE TIGHTENING TORQUES

Exhaust valve support, valve cover

Seal

Stud

Exhaust valve pulley Stud

Thermostat valve cover Bolt

Water pump cover

AMNT.

1

5

9

4

6

3

2.0

2.2

1.3

2.8

0.7

1.0

0.8

20

22

13

28

7

10

8

Bolt

Water drain bolt

THREAD SIZE

M14 x 1.25

M8 x 1.25

M8 x 1.25

M8 x 1.25

M5 x 0.8

M6 x 1.0

M6 x 1.0

2

1

0.8

1

8

10

M6 x 1.0

M6 x 1.0

Radiator Stud 2 0.88M6 x 1.0

Radiator cover Bolt 1 0.55M5 x 0.8

Oil pump Bolt 2 0.55M5 x 0.8

Carburettor gasket Stud 4 0.88M6 x 1.0

Air filter Bolt 2 0.55M6 x 1.0

Silencer NutStud bolt

Stud

22

3

1.81.0

0.8

1810

8

M8 x 1.25M8 x 1.25

M6 x 1.0

LOCTITE bolt securing adhesive

Oil change drain plug 1 1.515M8 x 1.25

Left hand crankcase cover Bolt 6 0.55M6 x 1.0

Right hand crankcase cover Bolt 6 0.88M6 x 1.0

Oil pump cover Bolt 3 0.55M6 x 1.0

Crankcase Bolt 12 0.88M6 x 1.0

Oil seal support Bolt 1 1.616M8 x 1.25

Cover Bolt 2 0.88M6 x 1.0

Clutch housing Nut 1 770M12 x 1.0

Clutch spring Stud 5 0.66M5 x 0.8

Clutch disk cover Bolt 2 110M6 x 1.0

16

PARTS TO BE TIGHTENEDTIGHTENING TORQUE

m.KgNmOBSERVATIONS

Drive sprocket

Tachometer cog housing Stud

Rotor

AMNT.

1

1

6

0.5

60

5

Nut

THREAD SIZE

M6 x 1.0

M6 x 1.0

1

1

1.5

8

15

80M12 x 1.25

Nut

Stop lever Stud 1 1.414M6 x 1.0 LOCTITE bolt securing adhesive

Change pedal Stud 1 1.515M6 x 1.0

Starter motor

17

MODEL GPR Racing 125 c.c.

STEERING SYSTEM Type of steering bearing

FRONT SUSPENSION Free length of forks spring Spring strength Travel Oil/bar capacity Type of oil

Rigid ball bearing

851 mm845 mm

20 N/mm

110 mm

340 cm3

FSAE 7.5W fork oil or higher

REAR SWINGING ARM At the end At the side

REAR SUSPENSION Shock absorber travel Free length of spring Length of spring fitted Spring strength

34 mm140 mm130 mm100 N/mm (0

18

MODEL GPR Racing 125 c.c.

FRONT DISK BRAKES Type Disk width Brake pad thickness

VENTILATED hydraulic disk4.0 mm3.5 mm4.5 mm1.5 mm

LEVERS AND TWISTGRIP Brake lever clearance (at the end)

Clutch lever clearance (at the end)

Throttle twist grip clearance

10 ~ 15 mm

10 ~ 15 mm

2 6 mm

REAR DISK BRAKES Type Inner diameter of brake drum Brake shoe thickness

VENTILATED hydraulic disk4.0 mm3.5 mm4.5 mm1.5 mm

19


VOLTAGEIgnition system: Ignition point (B.T.D.C) Advance type

12V

17 a 1.500 rpmDigital

IGNITION COIL Model Primary winding resistance Secondary winding resistance

3RW/YAMAHA0.23 20%7.9 k 20%

DIU Model of magneto/manufacturer Detector coil resistance Generator coil resistance Generator coil resistance Model of DIU/manufacturer

F4FU/YAMAHA310 20% W/R-W/L730 20% B/R-G/W600 20% G/L-G/W1D0/YAMAHA

SPARK PLUG CONNECTOR Type Resistance

Resin5K 20% a 20 C

CHARGING SYSTEM Type Magneto flywheel Model/Manufacturer Output Charging coil resistance (colour of the conductors)

Magneto

F4FU / YAMAHA14V 170 W 5000 rpm

0.6 20% a 20 C W-W

LIGHTING VOLTAGE (Min) (Max)

12V / 3.000 rpm15V / 8.000 rpm

RECTIFIER/ REGULATOR Type Model Voltage regulated without charge Capacity Resistance limit voltage

Shortcircuit type semiconductor SH629B-11/SHINDENGEN14.1 ~ 14.9 V25 A200 V

20


HORN Type Quantity Maximum current

Flat11,5 A (12V)

TURN INDICATOR RELAY Frequency Power

65 ~ 100 cycles/mnute10W x 2

SAFETY CIRCUIT Type Individual circuit current x quant. Main Reserve

Fuse

15A x 1 7,5A x 1

STARTER RELAY Type Model Nominal voltage Minimum functioning voltage Coil resistance

Electromagnetic12 V 180 A12 V8 V4.2 ~ 4.6 a 20 C

STARTER MOTOR Output power Length of the brushes Spring pressure Commutator diameter Depth of the mica

0.2 kW 5x7x7 mm

4.9 N 20%17.6 mm

1.35 mm

21

The following table specifies torques for standard ISO fixing devices. The torque specifications for special components or assemblies are indicated in the respective chapters of this manual.

To prevent distortions, tighten assemblies with various fixing devices progressively and in a crossed or alternating manner until the specified torque is reached. Unless stated otherwise, the specified torques require threads to be clean and dry. Components should be at room temperature.

A: Distance between flat surfaces.

B: Outer diameter of the thread.

(A) NUTGENERAL TORQUE SPECIFICATIONS

(B) BOLTNm Kgf.m ft.lb

10 mm

12 mm

14 mm

17 mm

19 mm

22 mm

6 mm

8 mm

10 mm

12 mm

14 mm

26 mm

6

15

30

55

85

130

0,6

1,5

3,0

5,5

8,5

13,0

4,3

11

22

40

61

94

22

CHASSIS TIGHTENING TORQUES

DESCRIPTION OF SECURING DEVICETIGHTENING TORQUE

(m-Kg)

CHASSIS TIGHTENING TORQUES

M8x1.25 FOOTREST SUPPT. SCTO.- RIDER FOOTREST S.D.

M6x100 INSTRUM.-CHASSIS SUPPORT SECURING DEV.

M10xl.5 10.9 TOP SEC. SHOCK-CHASSIS SEC.DEV.

MI0x1.5 10.9 SHOCK-SWING.ARM BOTTOM SEC.DEV.

M8x1.25 12.9 ENGINE-CHASSIS CRADLE SEC. DEV

M8x1.25 8.8 REAR SUBCHASSIS CHASSIS SEC.DEV.

M8X125 12.9 CYL.HEAD BRACE-CHASSIS SEC.DEV.

M8x125 12.9 REAR ENGINE-CHASSIS SEC.DEV.

M10x150 12.9 FRONT ENGINE-CHASSIS SEC.DEV.

M8x125 12.9 ENGINE CYL.HEAD-BRACE SEC.DEV.

M14x200 SWINGING ARM AXLE- CHASSIS SEC.DEV.

M8x1.25 RIDER FOOTREST SUPPORT-CHASSIS SEC.DEV.

M8x1.25 PILLION FOOTREST SUPPT.-CHASSIS SEC.DEV.

M20x100 STEERING FORK - CHASSIS SEC.DEV.

M8x125-8 EXHAUST PIPE-CYLINDER SEC.DEV.

M8x125-8 EXHAUST PIPE-CHASSIS SEC.DEV

SILENCER-SUPPORT SEC.DEV.

STEERING LOCK-FORK PLATE SEC.DEV. M8xl25

M8x125 TOP PLATE LOCK SEC. DEV.

M5x80 COUNTERWEIGHT-HANDLEBARS SEC.DEV.

M8x125 SEMI-HANDLEBAR PLATE SEC.DEV.

HANDLEBAR PLATE PLATE SEC.DEV.

M14x150 FRONT WHEEL FORK SEC.DEV.

MAX. TORQUE(m-Kg)

0,8-1 1

4,5-5,5 5,5

4,5-5,5 5,5

2,5-2,9 2,9

1,7-1,9 1,9

2,5-2,9 2,9

2,5-2,9 2,9

5,5-5,9 5,9

2,5-2,9 2,9

7-8 8

1,7-1,9 1,9

1,7-1,9 1,9

1,7-1,9 1,9

3-3,5 3,5

1,7-1,9 1,9

1,7-1,9 1,9

1,7-1,9 1,9

1,7-1,9 1,9

0,35-0,45 0,45

1,7-1,9 Sealed 1,9

1,7-1,9 1,9

7-8 8

M8x125 FORK ARM LOCK SEC. DEV.

M10x1.5 FRONT BRAKE CALLIPER FORK SEC.DEV.

M16x200 REAR WHEEL SWINGING ARM SEC. DEV.

M8x125 PROP STAND CHASSIS SEC.DEV.

M6x100 10.9 REAR BRAKE DISK-WHEEL SEC. DEV.

M6x100 WHEEL TENSIONER- SWINGING ARM SEC.DEV.

M8x125 10.9 DRAG PLATE- WHEEL SEC.DEV.

M6x100 RADIATOR-CHASSIS SEC. DEV.

1,7-1,9 1,9

3,5-4 Sealed 4

11-13 15

1,7-1,9 1,9

1-1,2 Sealed 1,2

0,8-1 1

2,5-2,9 Sealed 2,9

0,8-1 1

M8x1.25 FOOTREST SUPPT. SCTO.- RIDER FOOTREST S.D.

M6x100 INSTRUM.-CHASSIS SUPPORT SECURING DEV.

M10xl.5 10.9 TOP SEC. SHOCK-CHASSIS SEC.DEV.

MI0x1.5 10.9 SHOCK-SWING.ARM BOTTOM SEC.DEV.

M8x1.25 12.9 ENGINE-CHASSIS CRADLE SEC. DEV

M8x1.25 8.8 REAR SUBCHASSIS CHASSIS SEC.DEV.

M8X125 12.9 CYL.HEAD BRACE-CHASSIS SEC.DEV.

M8x125 12.9 REAR ENGINE-CHASSIS SEC.DEV.

M10x150 12.9 FRONT ENGINE-CHASSIS SEC.DEV.

M8x125 12.9 ENGINE CYL.HEAD-BRACE SEC.DEV.

M14x200 SWINGING ARM AXLE- CHASSIS SEC.DEV.

M8x1.25 RIDER FOOTREST SUPPORT-CHASSIS SEC.DEV.

M8x1.25 PILLION FOOTREST SUPPT.-CHASSIS SEC.DEV.

M20x100 STEERING FORK - CHASSIS SEC.DEV.

M8x125-8 EXHAUST PIPE-CYLINDER SEC.DEV.

M8x125-8 EXHAUST PIPE-CHASSIS SEC.DEV

SILENCER-SUPPORT SEC.DEV.

STEERING LOCK-FORK PLATE SEC.DEV. M8xl25

M8x125 TOP PLATE LOCK SEC. DEV.

M5x80 COUNTERWEIGHT-HANDLEBARS SEC.DEV.

M8x125 SEMI-HANDLEBAR PLATE SEC.DEV.

HANDLEBAR PLATE PLATE SEC.DEV.

M14x150 FRONT WHEEL FORK SEC.DEV.

M8x125 FORK ARM LOCK SEC. DEV.

M10x1.5 FRONT BRAKE CALLIPER FORK SEC.DEV.

M16x200 REAR WHEEL SWINGING ARM SEC. DEV.

M8x125 PROP STAND CHASSIS SEC.DEV.

M6x100 10.9 REAR BRAKE DISK-WHEEL SEC. DEV.

M6x100 WHEEL TENSIONER- SWINGING ARM SEC.DEV.

M8x125 10.9 DRAG PLATE- WHEEL SEC.DEV.

M6x100 RADIATOR-CHASSIS SEC. DEV.

23

DESCRIPTION OF SECURING DEVICETIGHTENING TORQUE

(m-Kg)

LOCKTITE 243-TYPE THREAD SEALER

M6x100 10.9 FRONT BRAKE DISK-WHEEL SEC. DEV.

M10x150 10.9 BRAKE BRACE SEC. DEV.

M6x18.8 REAR BRAKE CYLINDER SEC. DEV.

4.8 AUTHOR. FAIRING SUPPORTS SEC. DEV.

4.8 AUTHOR. FAIRING COVER SEC. DEV.

M5x80 VARIOUS METAL PARTS TO CHASSIS SEC. DEV.


M8xl25 VARIOUS METAL PARTS TO CHASSIS SEC. DEV.

M5x80 VARIOUS PLASTIC PARTS TO CHASSIS SEC. DEV.


MAX. TORQUE(m-Kg)

1-1,2 Sealed 1,2

3,5-4 4

0,8-1 1

0,1-0,2 0,2

0,1-0,2 0,2

0,35-0,45 0,45

0,8-1 1

1,5-1,9 1,9

0,1-0,2 0,2

0,2-0,35 0,35

LOCKTITE 243-TYPE THREAD SEALER

M6x100 10.9 FRONT BRAKE DISK-WHEEL SEC. DEV.

M10x150 10.9 BRAKE BRACE SEC. DEV.

M6x18.8 REAR BRAKE CYLINDER SEC. DEV.

4.8 AUTHOR. FAIRING SUPPORTS SEC. DEV.

4.8 AUTHOR. FAIRING COVER SEC. DEV.



M8xl25 VARIOUS METAL PARTS TO CHASSIS SEC. DEV.



24

INTRODUCTION

This chapter contains all the necessary information for carrying out recommended inspections and adjust-ments. If followed correctly, these preventative maintenance procedures will ensure a reliable operation of the machine and a longer operating life. The need for costly servicing will be significantly reduced. This information applies not only to machines already in service but also new machines in preparation for being sold. All technical assistance staff should familiarise themselves with the whole of this chapter.

PERIODICAL MAINTENANCE/LUBRICATION INTERVALS

INTRODUCTION

PERIODICAL MAINTENANCE/LUBRICATION INTERVALS

N ELEMENT1000

km/2m

1

SERVICE

2

3

4

5

7

8

9

10

11

Crankcase oil

Crankcase oil

Spark plug

Spark plug

Air filter

Coolant

Coolant

Radiator

Mileometer resend

Handlebars

6 Carburettor

12

13

14

15

16

18

19

20

21

22

Brake levers

Clutch lever

Brake pads

Flexible brake hoses

Brake liquid

Drive chain

Security locks

Drag plate

Front fork

Check level

Change

Check electrode gap

Replacement

Clean

Check level

Change

Clean externally

Lubrication

Check for damage and distortion

Adjust and clean

Lubrication

Adjust free play

Check wear

Check condition

Check level

Check condition and tension

Replacement

Check

Check the security locks

Check

Change17 Brake liquid

Drive chain

5000km/12m

10000km/24m

15000km/36m

20000km/36m

25000km/60m

X X X

X X X

X X X

X X

X X X X X X

X X X X X X

X X X X

X X

X X

X X X

X X X X X X

X X X X X X

X X X X X X

X X X X X X

X X

X X X

X X X X X X

X X X X X

X X X

X X X X X

X X X X

X

Every 2 years

25

* It is recommended that these elements are checked by an authorised DERBI dealer.

N ELEMENT1000km/2m

23

SERVICE

24

25

26

27

29

30

31

32

33

Front forks

Rear shock absorber

Electrical wiring

Front headlight

Tyres

Wheels

Inlet reeds

Cylinder head, cylinder and piston

Piston segments

28 Tyres

34

35

36

37

38

Piston segments

Cylinder head bolts/nuts

Fuel and oil pipes

Fuel and oil pipes

Brakes

Change the oil

Check

Check

Height adjustment

Check wear

Check

Check

Clean

Check

Pressure

Replacement

Check tightness

Check

Replacement

Machine test and check

Check and purge if necessaryOil pump

5000km/12m

10000km/24m

15000km/36m

20000km/36m

25000km/60m

X X

X X

X XX XX

X

X

X

X

X

X

X

X

X

X

X

X X X

X X

X X

X X X

X X

X X X X

X X

X X X

23

24

25

26

27

29

30

31

32

33

28

34

35

36

37

38

X X X

X X X X

X XX

X XX

26

DISMANTLING

1. Extract: - Seat.

N.B.INSERT THE IGNITION KEY, TURN IT CLOCKWISE A QUAR-TER TURN AND THEN REMOVE THE SEAT.

2. Extract:Passenger seat.- The nut under the seat must be unscrewed.- Pull the seat forwards.

3. Extract:- Cowling.

The black cover (1) in the figure must be be removed by uns-crewing the bolts (2) on both sides.

The studs (4) on both sides then need to be unscrewed, and the clamp securing the exhaust pipe. The cowling (3) can then be removed by pulling out backwards.

4. Closing:- Dismantle:- Top side cover.

To do so, the front air inlet (5) needs to be removed on the corresponding side together with its securing bolts (6).

Then remove the bolts securing the cover (indicated in the fugure).

DISMANTLING

27

5. Dismantle:Bottom fairingRemove the screws located at the bottom (keel joint) and another located at the front.

6. Dismantle:Fuel tank. Remove the 3 screws in the picture.

N.B.THE FUELTAP WORKS BY PRESSURE. IF THIS IS WORKING PROPERLY, THE TANK DISMANTLING PROCESS IS VERY STRAIGHTFORWARD AND IS OUTLINED BELOW:- DISCONNECT THE FUEL LEVEL SENSOR (1).- REMOVE THE ENGINE BREATHER PIPE (2).- REMOVE THE FUEL OUTLET PIPE (3).

IF HOWEVER THE TAP IS NOT WORKING WELL, THE PRO-CESS TO FOLLOW IS:- TURN THE KEY TO THE OFF POSITION.- DISCONNECT THE NEGATIVE BATTERY TERMINAL.- OPEN THE FUEL TANK CAP (TO REDUCE THE PRESSURE IN THE TANK).- EMPTY THE PETROL FROM THE TANK USING A PUMP.- THEN FOLLOW THE PROCESS DESCRIBED PREVIOUSLY.

WARNINGTHE TANK WILL NEVER BE COMPLETELY EMPTIED. TAKE CARE THEREFORE TO CLEAN UP ANY SPILLAGES THAT OCCUR, WHICH MAY DIRTY THE FAIRING OR CHASSIS.

REFITTING

- This is a reversal of the REMOVAL procedure.- Take note of the following points:

Fit:1) Fuel tank2) Bottom fairing3) Front air inlet4) Top side covers5) Cowling6) Seats.

REFITTING

28

CO MEASUREMENT AND VACUUM RUNNING ADJUSTMENT

1. Start the engine and leave to warm up for a few minutes.

2. Connect:-An inductive tachometer to the spark plug lead.

N.B.THE IDLING REGULATOR IS ACCESSED FROM THE LEFT HAND SIDE OF THE MACHINE. SEE THE COVER DISMAN-TLING METHOD IN THE PREVIOUS SECTION.

3. Check:- Idle speed (standard).

Outside that specified => Adjust.

Turn the no load running screw (1) inwards or outwards un-til the specified no load running is obtained.

No load running: 1.250 ~ 1.450 rpm

4. Fit:- the CO meter into the exhaust silencer.

CO concentration: 3,0 ~ 5,0 %


CO MEASUREMENT AND VACUUM RUNNING ADJUSTMENT

29

5. Adjust:- CO concentration.

Adjustment steps:- Turn the mixture screw inwards or outwards until the spe-cified CO concentration is obtained.

Adjustment band: Rub probe point~ up to 6 turns outwards.

N.B.TURN THE NO LOAD RUNNING SCREW (2) TO ADJUST THE ENGINES NO LOAD RUNNING, SINCE THE CO CONCENTRATION ADJUSTMENT MAY AFFECT THE NO LOAD RUNNING.

- After adjusting, check the CO concentration and remove the CO probe. Ensure that there are no variations in the idle speed.

ADJUSTING THE THROTTLE CABLE

N.B.BEFORE ADJUSTING THE THROTTLE CABLE, THE NO LOAD RUNNING MUST BE ADJUSTED.

1. Check:- Throttle cable play (a). Outside that specified => Adjust.

Clearance: 26 mm. In the throttle twist grip plate:

2. Adjust:- Throttle cable play.

Adjustment steps:

N.B.NEVER ACCELERATE WHILE THE ENGINE IS STOPPING.

ADJUSTING THE THROTTLE CABLE

30

- Loosen the throttle cable locknut (2).

- Turn the adjuster (1) inwards or outwards until the speci-fied play is obtained.

Turning inwards (a) = Increasing the play. Turning outwards (b) = Reducing the play.

- Tighten the locknut.

N.B.IF THE PLAY IS STILL INCORRECT, ADJUST IT USING THE ADJUSTER BELOW THE TWIST GRIP.

WARNINGAFTER ADJUSTMENT, TURN THE HANDLE IN BOTH DI-RECTIONS TO ENSURE THAT THERE IS NO NO-LOAD VA-RIATION .

INSPECTING THE SPARK PLUG

1. Extract:- Spark plug connector.

- Spark plug.

ATTENTIONBEFORE REMOVING THE SPARK PLUG, BLOW AROUND IT WITH COMPRESSED AIR TO REMOVE ANY DIRT, THEREBY PREVENTING THIS FROM FALLING INTO THE ENGINE.

2. Check:- Spark plug type

Incorrect => Replace.

Standard spark plug: NGK BR8ES

3. Inspect:- Electrode (1).

Damage/wear => Replace.

- Insulator (2).

Abnormal colour => Replace.

The normal colour is light brown.

INSPECTING THE SPARK PLUG

31

4.Clean:- Spark plug(Clean the spark plug with a spark plug cleaner or wire brush)

5. Measurement:- Gap between the electrodes (a), (using a feeler guage).

Outside that specified => Adjust the gap.

Gap between electrodes: 0,7 mm

6. Fit:- Spark plug

Spark plug: 20 N.m ( 2 kgf.m)

N.B.- BEFORE REFITTING THE SPARK PLUG, CLEAN ITS SEA-TING SURFACE AND GASKET.

- IF NO TORQUE WRENCH IS AVAILABLE, A GOOD WAY OF JUDGING THE CORRECT TORQUE IS TO TIGHTEN (1) THE SPARK PLUG BY HAND AND THEN TIGHTEN IT FROM TO A TURN AS FAR AS (2).

- ALWAYS USE A NEW GASKET.

32

INSPECTING THE ENGINE OIL LEVEL

1. Place the motorcycle on a flat surface.

N.B.MAKE SURE THE MOTORCYCLE IS VERTICAL WHEN CHEC-KING THE OIL LEVEL.


3. Stop the engine.

4. Check the oil level in the inspection window (1) (located in the right hand crankcase cover).

N.B.: THE OIL LEVEL MUST BE BETWEEN THE MAXIMUM (2) AND THE MINIMUM (3).

5. If the oil is below the minimum level, add oil up to the correct level.

RECOMMENDED OIL FOR THE ENGINE

Recommended oil for the engine: SAE 10W40 or higher


7. Stop the engine.

N.B.WAIT A FEW MINUTES FOR THE OIL TO PERCOLATE DOWN BEFORE RE-CHECKING THE OIL LEVEL.

CHANGING THE ENGINE OIL


2. Stop the engine and place a container under the engine.

3. Extract:- Oil filler cap (1).- Oil drain plug (2).Drain the oil from the crankcase.

4. Fit:- Drain plug (1).

Drain plug: 2,0 Kgf.m (20 N.m)

INSPECTING THE ENGINE OIL LEVEL

RECOMMENDED OIL FOR THE ENGINE

CHANGING THE ENGINE OIL

33

5. Replenish:- Oil in the crankcase.

Quantity of oil: 0,8 L

6. Check:- The engine oil level.

See INSPECT THE ENGINE OIL LEVEL section

INSPECTING THE EXHAUST SYSTEM

1. Inspect:- Bolts (1) (exhaust pipe)

Loose/damaged => Tighten/replace.

- Gasket (exhaust pipe).Leaking exhaust fumes => Tighten/replace.

Bolt: 8 N.m (0,8 kgf.m)

2. Inspect:Bolts securing the exhaust pipe to the chassis. Loose/damaged => Tighten/replace.

Bolt: 17-19 N.m (1,7-1,9 kgf.m)

RENEWING AIR FILTER

N.B.IF THE MACHINE IS USED IN THE RAIN OR IN DUSTY CON-DITIONS, THE FILTER SHOULD BE CHECKED AND REPLACED MORE FREQUENTLY THAN THAT SET OUT IN THE MAINTE-NANCE TABLE OR PROGRAMMED IN THE USE AND MAIN-TENANCE MANUAL.

Extract:Proceed in the following way:

- Rest the machine on the prop stand. Remove the fuel tank (see previous sections).

INSPECTING THE EXHAUST SYSTEM

34

- To remove the top cover, remove the clips securing the filter body (see picture).

- Extract the foam air filter, wash it in soapy water, then wring it out and dry it completely. Next, soak it in special oil for fil-ters and refit it.

Fitting:- Fit in reverse order to dismantling.

- Then refit the top filter cover.

- Seal the box cover with silicon.

Recommended oil: AGIP FILTER OIL

WARNINGNEVER USE PETROL TO CLEAN THE AIR FILTER ELEMENT. A SOLVENT OF THIS TYPE MAY CAUSE FIRE OR EXPLOSION.

ADJUSTING THE CLUTCH

Check:- Clutch cable play (a).


Clearance (clutch lever): 10 15mm at the end of the lever.

2. Adjust:- Clutch cable play.

Adjustment steps:Lever end.

- Turn the adjuster (1) inwards or outwards until the specified play is obtained.

Turning inwards (a)= Increases the play. Turning outwards (b) = Reduces the play.

JUS G C U C

35

ADJUSTING THE FRONT BRAKES

This machine is fitted with hydraulically activated disk brakes. This type of brakes comes with adjustment factory set.You must check that the brake fluid level is between the maxi-mum and minimum.

N.B.REMEMBER THAT THE LEVEL WILL BE AFFECTED BY THE DE-GREE OF BRAKE PAD WEAR.

ADJUSTING THE REAR BRAKES

1. Check:- Brake pedal clearance (a).


Clearance: 5 - 10 mm

2. Adjust:- Brake pedal clearance.

Adjustment steps: Unscrew the nut (1):

Raise or lower the activator (2) to decrease or increase the lever free clearance.

ATTENTIONENSURE THAT THE BRAKES ARE NOT BINDING AFTER AD-JUSTING THE PLAY.

INSPECTING THE BRAKE PADS

1. Apply the brake pedal or lever.

2. Inspect:- Pads.

- Measure the brake pad lining thickness. If either of them is below the service limit => Replace both pads.

Service limit (lining) => 1.5mm.

ADJUSTING THE FRONT BRAKES

ADJUSTING THE REAR BRAKES

Joc palanca fre

INSPECTING THE BRAKE PADS

36

ADJUSTING THE TIMING CHAN TENSION

1. Put the motorcycle on the centre stand.

2. Check:- Drive chaIn tension (a).

Outside that specified => Adjust.(distance between the chain guide and the furthest point vertically)

Drive chain tension: 11 mm

3. Loosen:- Axle nut (1) (both sides).

4. Loosen: - Axle (2).

5. Adjust:- Drive chain tension.

- Move the axle inwards or outwards using the bolt (3) until the specified tension is obtained.

6. Tighten the axle nuts to the nominal torque.

Nut (rear wheel axle): 70-80 N.m (7-8 kgf.m)

JUS G G C S O

37

INSPECTING THE TYRES

1.Measurement:- Tyre pressure


WARNINGTYRE PRESSURE SHOULD ONLY BE CHECKED OR ADJUS-TED WHEN THEIR TEMPERATURE IS THE SAME AS AMBIENT TEMPERATURE. THE TYRES AND SUSPENSION SHOULD BE ADJUSTED IN ACCORDANCE WITH THE TOTAL LOAD RI-DER, PILLION PASSENGER AND ACCESSORIES (COVERS, SIDEBAGS, ETC. IF THESE ARE APPROVED FOR THIS MO-DEL) AND IN ACCORDANCE WITH THE RIDING SPEED OF THE MOTORCYCLE.

NEVER OVERLOAD THE MOTORCYCLE.

RIDING AN OVERLOADED MOTORCYCLE MAY CAUSE DA-MAGE TO THE TYRES, ACCIDENTS OR INJURY.

2. Inspect:- Tyre surfaces.Damage/wear => Replace.

Minimum tread depth: 0,8 mm

(1) Tread.(2) Side wall.(3) Wear indicator.

INSPECTING THE TYRES

BASIC WEIGHT: With oil and full fuel tank 131 kg

TYRE PRESSURES (COLD): FRONT TYRE REAR TYRE

Rider only

With pillion passenger

170 kPa1,7 kg/cm2

190 kPa1,9 kg/cm2

190 kPa1,9 kg/cm2

210 kPa2,1 kg/cm2

BASIC WEIGHT: With oil and full fuel tank

38

WARNINGRIDING WITH WORN TYRES IS DANGEROUS. WHEN THE TYRE TREAD BEGINS TO SHOW SIGNS OF WEAR, THE TYRES SHOULD BE REPLACED IMMEDIATELY.

MENDING A PUNCTURED INNER TUBE IS NOT RECOM-MENDED. IF IT IS ABSOLUTELY NECESSARY TO DO SO, TAKE GREAT CARE, AND REPLACE THE INNER TUBE WITH A GOOD QUALITY ONE AS SOON AS POSSIBLE.

NEVER USE TUBELESS TYRES ON A WHEEL DESIGNED FOR TYRES WITH INNER TUBES. THE TYRE MAY FAIL, AND THE RESULTING BLOW-OUT MAY CAUSE AN ACCIDENT.

Wheels for tubed tyres => use only tubed tyres.

Wheels for tubeless tyres => use only tubeless tyres.

- Ensure that the tube is correctly fitted when using tyres with inner tubes.

WARNINGAFTER FITTING THE TYRE, DRIVE WITH MODERATION FOR A PERIOD TO ALLOW PARAFFINS TO BE CLEANED OFF THE TYRE BY THE ROAD SURFACE.

39

INSPECTING AND TIGHTENING THE SPOKES

1. Inspect: - Spokes (1).

Warps/damage => Replace.

INSPECTING THE WHEELS

1. Inspect:- Wheels

Damaged/distorted => Replace.

N.B.ALWAYS CARRY OUT WHEEL BALANCING WHEN A TYRE OR A WHEEL IS FITTED OR REPLACED.

WARNINGNEVER ATTEMPT TO REPAIR A WHEEL.

INSPECTING THE BATTERY

1. Extract:- Fuel tank.

See SEATS, FAIRING AND FUEL TANK section.

2. Inspect:- Battery terminals.

Dirtiness => Clean with wire brush. Poor connection => Put right.

INSPECTING AND TIGHTENING THE SPOKES

INSPECTING THE WHEELS

INSPECTING THE BATTERY

40

N.B.AFTER CLEANING THE TERMINALS, APPLY A THIN LAYER OF GREASE TO THEM.

Replace the battery if:- The voltage falls below a specific value.

ATTENTIONBEFORE USING THE NEW BATTERY, IT MUST BE CHARGED TO ENSURE MAXIMUM PERFORMANCE.

3. Fit:- Battery.

4. Connect:- Battery cables.

ATTENTIONCONNECT THE POSITIVE CABLE (1) TO THE BATTERY FIRST AND THEN THE NEGATIVE CABLE (2).

5. Fit:Fuel tank


INSPECTING THE FUSES

ATTENTIONALWAYS DISCONNECT THE MAIN SWITCH WHEN INSPEC-TING OR REPLACING A FUSE. FAILURE TO DO SO MAY RE-SULT IN A SHORT CIRCUIT.

1. Lift out and remove to the left- fuel tank


Fuse box (1).

INSPECTING THE FUSES

41

2. Inspect:- Fuse.

Steps for the inspection:- Connect the multi-meter to the fuse to check if there is a circuit.

N.B.ADJUST THE MULTI-METER SELECTOR TO X.

If the meter indicates , replace the fuse.

3. Replacing:- Blown fuse.

Replacement steps:- Disconnect the main switch.

- Fit a new fuse with the correct amperage.

- Turn on the switches to check the functioning of the corres-ponding electrical devices.

- If the fuse blows again immediately, inspect the electrical circuit.

WARNINGNEVER USE A FUSE WITH AN AMPERAGE OTHER THAN THAT SPECIFIED. NEVER USE OTHER MATERIALS INSTEAD OF A FUSE. AN INCORRECT FUSE MAY CAUSE MAJOR DA-MAGE TO THE ELECTRICAL SYSTEM, MALFUNCTIONING OF THE LIGHTS AND IGNITION, AND MAY ALSO CAUSE A FIRE.

4. Fit:- Fuse box.- Fuel tank


42

ADJUSTING THE HEADLIGHT BEAM

1. Adjustment

- Headlight beam heightTo adjust the height, turn the screw (2) in one of two direc-tions:

SCREWING IN => Lower UNSCREWING => Raise

2. Adjust:

- Headlight dispersion.To adjust the headlight width, turn the screw (1) in one of two directions:

SCREWING IN => Increase UNSCREWING => Decrease

REPLACING THE HEADLIGHT BULBS

1. Extraiga:- Headlight bulb holder.

Disconnect the bulb holder, turn it a quarter turn (see photo) and pull it out.

Change the blown bulb and refit by repeating the process in the reverse order.

2. If the whole headlight unit needs to be changed, carry out the following process:- Disconnect the bulb holder (1).

- Remove the screws (2) at the top, on the bottom inside and outside under the cover (3).

The headlight can now be removed though the inside of the front fairing.

ADJUSTING THE HEADLIGHT BEAM

REPLACING THE HEADLIGHT BULBS

43

WARNINGKEEP INFLAMMABLE PRODUCTS AND HANDS AWAY FROM THE BULB WHILE IT IS LIT, BECAUSE IT WILL BE HOT. DO NOT TOUCH IT UNTIL IT COOLS DOWN.

ATTENTIONAVOID TOUCHING THE BULB GLASS. KEEP IT FREE OF OIL. IF NOT, THE TRANSPARENCY OF THE GLASS, THE DURABI-LITY OF THE BULB AND THE AMOUNT OF LIGHT EMITTED WILL BE AFFECTED. IF THE BULB BECOMES SOILED WITH OIL, CLEAN IT CAREFULLY WITH A DAMP CLOTH OR WITH ALCOHOL OR THINNER.

CHANGING TURN INDICATOR BULBS

1. Extract:- Glass screw (1).

2. Dismantle:- Glass cover.- Power supply terminals

3. Turn the bulb carefully and pull out forwards.

4. Change the bulb (if necessary).

5. Reverse the dismantling process and refit the turn in-dicator.

CHANGING THE SIDE AND BRAKE LIGHT BULBS 1. Extract:- Passenger seat.

2. To remove the BRAKE LIGHT, turn the bulb holder (1) in an anticlockwise direction and pull out.

3. To remove a SIDE LIGHT bulb, pull out the bulb holder (2).

CHANGING TURN INDICATOR BULBS

C G G S G U S

44

4. Should the headlight need to be completely dismantled, the two screws (1) securing the unit to the cowling need to be removed, and the unit removed by pushing carefully through the rear of the cowling.


N.B.:THERE IS NO NEED TO REMOVE THE ENGINE TO DISMAN-TLE THE FOLLOWING COMPONENTS:- CYLINDER HEAD- CYLINDER- PISTON- MAGNETO FLYWHEEL

DISMANTLING THE SIDE COVERS AND FUEL TANK

4. Extract:- FRONT covers- Riders seat.- Fuel tank

See SEAT, SIDE COVERS AND FUEL TANK section in CHAPTER 3.

ENGINE OIL

1. Drain:- Engine oil.

See the CHANGING ENGINE OIL section in Chapter 3.

BATTERY

1. Disconnect:- Battery.

ATTENTIONFIRST DISCONNECT THE NEGATIVE CABLE (1) FROM THE BATTERY AND THEN THE POSITIVE CABLE (2).


S G S CO S U

G O

BATTERY

Piloto 2

45

REMOVING THE ENGINE FROM THE CHASSIS

1. Dismantle side covers.

2. Remove the petrol tank.

3. Remove the exhaust pipe.

4. Remove the gear change lever.- Remove bolt (1).- Remove change backlash bush (2).

5.Remove chain.Remove chain coupling link clip.

6. Extract the radiator.Drain the cooling system.

7. Dismantling the carburettor.- Remove filter box-carburettor pipe (secured with a jubilee clip).

- Loosen jubilee clip on carburettor pipe to cylinder.

- Remove carburettor.

- Remove jubilee clip and pipe from cylinder head to carburettor.

REMOVING THE ENGINE FROM THE CHASSIS

46

Remove system inlet (1) and outlet (2) hoses and tank hose (3).

Remove radiator.

8. Extract oil pump cable. Remove cover.

47

Remove the retaining circlip with pulley and torsion recovery spring. - Extract cables and remove them from the engine.

9. Extract the oil tank to engine hose.- Remove the tank hose and plug it.

- Plug the oil tank outlet.

10. Remove the clutch operating cable.- Free the clutch cable from the handlebars.- Remove the the tensioning cable from the crankcase.- Remove the clutch operating cable.

11. Free exhaust valve operating cable.- Remove cover (1).

- Loosen cable by screwing in and extract it from the pulley.

- Unscrew the two tensioners and remove the cables.

12. Disconnect:- Stator coil connector.- Impulse coil connector.- Neutral switch connector.

Extract:- Spark plug connector.

48

12. Remove electrical connections.- Remove spark plug connector.- Remove the temperature meter cable.- Remove the magneto cable.- Remove earth cable from right hand side of the crankcase.- Remove neutral earth cable.- Remove starter motor power supply cable.- Remove cables from the coil.

13. Removing the engine cradle.- Remove the UNEX clamps.- Remove the 6 bolts securing the cradle to the engine and to the chassis.- Withdraw the engine cradle from below the machine.

14. Extracting the engine.Pull out the swinging arm axle without extracting it complete-ly, ensuring that it only joins the swinging arm and the chassis. Insert a support shaft into the other side joining only the swin-ging arm and chassis, to ensure that the swinging arm and chassis do not come loose.

Unfasten the engine from the top bracket. Remove the engi-ne.

N.B.IT IS ADVISABLE TO PLACE A SUPPORT UNDER THE ENGINE BEFORE FREEING IT FROM THE CHASSIS, TO AID IN THE DISMANTLING PROCESS.

CYLINDER HEAD, CYLINDER AND PISTON

1. Extract:- Nuts and washers (cylinder head).- The cylinder head and its gasket on the cylinder.

N.B.LOOSEN EACH OF THE 5 BOLTS A QUARTER TURN IN TURN, AND REMOVE THEM WHEN THEY ARE COMPLETELY LOOSE.LOOSEN THE NUTS IN THE ORDER SHOWN IN THE ADJO-INING PICTURE.CLEAN OFF GASKET DEBRIS AND CARBON DEPOSITS WITHOUT SCRATCHING OR WEARING DOWN THE SUR-FACES.

2. Extract:- Nuts and washers (cylinder base).- Clutch cable securing device.- Cylinder and its gasket.

CYLINDER HEAD, CYLINDER AND PISTON

49

3. Extract:- Gudgeon pin circlip.- Gudgeon pin.- Piston.- Connecting rod big end needle bearing assembly.

N.B.BEFORE REMOVING THE CIRCLIP FROM THE GUDGEON PIN, COVER THE BASE OF THE CYLINDER WITH A CLEAN CLOTH TO PREVENT ANYTHING FROM FALLING INTO THE ENGINE.

BEFORE REMOVING THE GUDGEON PIN, ELIMINATE THE ROUGH EDGES OF THE CICLIP GROOVE AND THE HOLE. ONCE THE ROUGH EDGING HAS BEEN ELMINATED, AND IF THERE IS STILL DIFFICULTY IN REMOVING THE GUD-GEON PIN, USE THE GUDGEON PIN EXTRACTOR.

Gudgeon pin extractor: 00M12501258

DISMANTLING THE REED VALVE

1. Extract:- The carburettor from the engine unit.- Closing bolts from the inlet nozzle.- Reed valve.

MAGNETO

N.B.THE MAGNETO CAN BE EXTRACTED WHILE THE ENGINE IS MOUNTED ON THE FRAME, BY DETACHING IT FROM THE LOWER LEFT HAND FAIRING

1. Extract:- Left hand crankcase cover.- Nut (magneto) (1).- Flat washer (2).

N.B.RELEASE THE MAGNETO NUT WHILE HOLDING THE MA-NETO WITH THE UNIVERSAL (MAGNETO) ROTOR HOLDER (3).

Holding the rotor: 00005253240

G O

DISMANTLING THE REED VALVE

50

2. Extract:- Magneto flywheel (1).- Pin.

N.B.EXTRACT THE MAGNETO FLYWHEEL USING THE ROTOR EXTRACTOR (2).CENTRE THE ROTOR EXTRACTOR ON THE MAGNETO FLYWHEEL. ENSURE THAT THE GAP BETWEEN THE EX-TRACTOR AND THE FLYWHEEL IS THE SAME AT ALL PO-INTS AFTER FITTING THE SECURING BOLTS. IF NECESSARY, LOOSEN ONE OF THE BOLTS TO ADJUST THE EXTRACTOR POSITION.

ATTENTIONCOVER THE END OF THE CRANKSHAFT WITH THE SPAN-NER TO PREVENT DAMAGE.

Magneto flywheel extractor: 00M12501259

3. Extract:- Plate (1).- Starter gear (2).

4. Extract:- Needle bearings (1).- Support shaft (2).

5. Extract:- Nut- Washer- Drag pinion

CLUTCH

N.B.THE CLUTCH ASSEMBLY CANNOT BE REMOVED WITH THE ENGINE MOUNTED ON THE FRAME. FOR THIS, SEE RE-MOVING THE ENGINE FROM THE CHASSIS.

1. Extract:- Right hand crankcase cover.

N.B.LOOSEN THE BOLTS FOLLOWING A DIAGONAL SEQUEN-CE. DRAIN THE OIL FROM THE CLUTCH UNIT.

CLUTCH

51

2. Extract:- Gasket.- Guide pins.

3. Extract:- Pressure plate bolts (1).- Clutch springs (2).- Pressure plate (3).- Friction disks (4).- Separators (5).- Spring (6).

N.B.LOOSEN THE PRESSURE PLATE BOLTS DIAGONALLY.

4. Extract:- Push rod 1- Ball- Locknut

N.B.FLATTEN OUT THE TAB OF THE TAB WASHER.LOOSEN THE CLUTCH HOUSING NUT WHILE HOLDING THE HOUSING WITH THE UNIVERSAL CLUTCH HOLDER .

Universal clutch holder: 00M12501260

52

5. Extract:- Clutch housing nut (1).- Tab washer (2).- Clutch housing (3).- Pressure washer (4).- Clutch bell casing (5).- Spacer (6).- Washer (7).

N.B.HOLD THE MAGNETO FLYWHEEL USING THE ROTOR HOL-DER. THEN LOOSEN THE ENGINE PINION NUT.

6. Extract:- Nut.- Special washer.- Crankshaft output gear- Pin.- Crankshaft housing cover

7. Extract:- Nut- Tab washer - Balancing (anti-vibration) gear.- Pin.

53

GEAR CHANGE SHAFT

N.B.THE GEAR CHANGE SHAFT CANNOT BE DISMANTLED WITH THE ENGINE MOUNTED IN THE FRAME. SEE REMO-VING THE ENGINE FROM THE CHASSIS.

1. Extract:- Gear change shaft (1).- Bolt (2).- Positioning cam (3)- Torsion spring (4).

CRANKCASE

1. Extract:- Bolts (crankcase).- Battery cable bracket.

N.B.UNDO THE BOLTS DIAGONALLY.

LOOSEN EACH BOLT A QUARTER TURN IN TURN, AND RE-MOVE THEM WHEN THEY ARE COMPLETELY LOOSE.

2. Position:- The segment of the gear selector in such a way that it can pass through the hole and enable the crankcases to be se-parated.

G C G S

CRANKCASE

54

3. Extract:- Right crankcase

N.B.PLACE THE ENGINE WITH THE LEFT HAND CRANKCASE FA-CING DOWN AND THEN INSERT A SCREWDRIVER IN THE CRANKSHAFT SEPARATING SLOTS (A).

4. Extract: Guide pins.

BALANCER, TRANSMISSION AND GEAR SELECTOR

1. Extract:- Gear fork 1 guide lever (short).- Gear fork 2 guide lever (long).- Gear selector (3).- Gear fork 1 (4).- Gear fork 2 (5).- Gear fork 3 (6).- Drive shaft assembly (7).- Driven shaft assembly (8).

2. Extract:- Balancing counterweight (9).

C , S SS O G S C O

55

3. Extract:- Neutral switch.

CRANKSHAFT

1. Extract:- Crankshaft with the rocker shaft.

N.B.DETACH THE CRANKSHAFT USING THE CRANKCASE SEPA-RATOR TOOL (2).

TIGHTEN THE CRANKCASE SEPARATOR BOLTS RIGHT DOWN, BUT ENSURE THAT THE BODY OF THE TOOL IS PA-RALLEL WITH THE CASING. IF NECESSARY, LOOSEN ONE OF THE BOLTS A LITTLE TO ADJUST THE POSITION OF THE CRANKCASE SEPARATOR.

Crankcase separator: 00M12501261

CYLINDER HEAD

1. Eliminate:- Carbon deposits sediments (and gasket remains). N.B.AVOID USING ANY SHARP EDGED INSTRUMENT THAT CAN CAUSE DAMAGE AND SCRATCHING:

- IN THE SPARK PLUG THREAD

2. Inspect:- Cylinder head

Scratches/damage => Replace.

CRANKSHAFT

CYLINDER HEAD

56

3. Measurement:- Distortion

Outside that specified => Rectify.

Cylinder head distortion: less than 0.03mm

Steps for measuring the distortion and rectification:- Place a ruler (1) and a thickness calliper (2) on the head cylinder surface, as in the figure to the side.

- Measure the distortion.

- If the distortion is outside that specified, rectify the cylinder head.

- The lines in the picture correspond to the different directio-ns that need to be checked with the ruler.

- Lay a 400 600 file on a flat surface and rectify the cylin-der head surface by filing with a figure eight movement.

N.B.TURN THE CYLINDER HEAD SEVERAL TIMES TO AVOID AN EXCESSIVELY UNEVEN REMOVAL OF MATERIAL.

CYLINDER AND PISTON

1. Inspect:

- Cylinder and piston walls.

Vertical scratches=> Rectify or replace the cylinder and the piston.

2. Measurement:- Cylinder-piston play

Steps for measuring: Step 1:- Measure cylinder diameter C with an internal calliper.

N.B.MEASURE THE DIAMETER C OF THE CYLINDER ACROSS AND AT A RIGHT ANGLE TO THE CRANKSHAFT. THEN CAL-CULATE THE AVERAGE MEASUREMENT.

CYLINDER AND PISTON

57

- If it is outside that specified , rectify or replace the cylinder and replace the piston and the rings together.

Step 2:- Measure the base of the piston P with a micrometer. (a) 10 mm from the piston base.

- If it is outside that specified , replace the piston and the rings together.

Step 3:- Calcule el juego cilindro - pistn, empleando la siguiente frmula:

Cylinder-Piston clearance: Diameter of the cylinder C Diameter of the piston base P.

Clearance (Cylinder-Piston): 0.045 0.050 mm Limit: 0.10 mm

- If it is outside that specified, rectify or replace the cylinder, the piston and its rings all together.

DIAMETER OF THE CYLINDER C

OVALNESS R

56.00 56.02 mm

0.05 mm

0,01 mm

TAPER LIMIT T

C = D MAXIMUM

R = (D1, D3 O D5 MAXIMUM) - (D2,D4 O D6 MINIMUM)

T = (D1 O D2 MAXIMUM) - (D5 O D6 MAXIMUM)

DIAMETER OF THE PISTON P.

55.950 59.955 mmSTANDARD

0.25 mm

0.50 mmOVER-MEASUREMENT

58

INSPECTING THE PISTON RINGS

1. Measure:- Lateral clearance.

Outside that specified => Replace the piston and its rings all together.

N.B.ELIMINATE THE CARBON DEPOSITS FROM THE PISTON RING GROOVES, BEFORE MEASURING THE LATERAL PLAY.

Lateral play (piston rings):

Top ring : 0.02 0.06 mm

Secondary (scraper) ring: : 0.035 0.070 mm

2. Position:- The piston rings (in the cylinder).

N.B.PUSH THE RING WITH THE HEAD OF THE PISTON IN SUCH A WAY THAT IT IS POSITIONED PARALLEL TO THE CYLINDER BASE.

(a) 5mm.

3. Measure:- Clearance between points

Outside that specified => Replace.

Clearance between points: Top ring : 0.30 0.45 mm

Second ring (scraper) : 0.30 0.45 mm

INSPECTING THE PISTON RINGS

59

CRANKSHAFT

1. Measure:- Crankshaft lack of alignment

Outside that specified => Replace the crankshaft and/or bearings.

N.B.MEASURE CRANKSHAFT POOR ALIGNMENT BY SLOWLY TURNING THE CRANKSHAFT ASSEMBLY.

Poor alignment limit: 0,03 mm

2. Measure:- Connecting rod side clearance

Outside that specified => Replace the connecting rod big end bearing, crankshaft elbow and/or the connecting rod.

Connecting rod side clearance: 0.20 0.70 mm

3. Measure:- Crankshaft width

Outside that specified => Replace the crankshaft.

Crankshaft width: 57.90 57.95 mm

INSPECTING THE BALANCER

1. Inspect:- Balancer shaft

Wear/warping/damage => Replace.

C S

INSPECTING THE BALANCER

60

INSPECTING THE CLUTCH BELL HOUSING

1. Inspect:- Primary sprocket teeth (1).

- Bell housing sprocket teeth (2).

Wear/damage => Replace both sprockets.

Excessive noise when running => Replace both sprockets.

INSPECTING THE CLUTCH

1. Inspect:- Friction disks

Wear/damage => Replace the friction disk assembly.

2. Measure:- Thickness of the friction disks

Outside that specified => Replace the friction disk ass-embly.

Measure at 4 different positions.

Thickness (friction disks): 2.9 3.1 mm

3. Inspect:- SeparatorsDamage => Replace the separator assembly.

S C G C U C OUS G

S C G C U C

61

4. Measure:- Separator distortion

Outside that specified => Replace the separator assembly.

Take the measurement on a flat table with the aid of a thic-kness calliper (1).

Distortion limit (separators): less than 0,05mm.

5. Inspections:- Clutch springs.

Damage => Replace the spring assembly.

6. Measure:- Free length (springs) (a).

Outside that specified => Replace the spring assembly.

Free length (springs): 34.5 mm

7. Inspect:- Claws (of the bell housing) (1).

Edgings/wear/damage => Eliminate the rough edges or replace the bell housing.

- Clutch housing slots (2).

Rough edges/wear/damage => Replace the clutch housing.

N.B.ROUGH EDGES ON THE CLUTCH CLAWS AND ON THE CLUTCH HOUSING SLOTS LEAD TO IRREGULAR OPERA-TION.

62

INSPECTING THE ACTIONING ROD

1. Inspect:- Ball (1).

- Activating rod (2).

Wear/cracks/damage => Replace.

INSPECTION OF THE FORKS AND GEAR SELECTOR

1. Inspect:- Fork follower (1).

- Ends of the gear change forks (2).

Scratches/warping/wear/damage => Replace.

2. Inspect:- Gear selector slots.

Wear/damage/scratches => Replace.

- Gear change selector follower.

Wear/damage => Replace.

3. Inspect:- Gear change fork 1 centre right (1).- Gear change fork 2 top left (2).- Gear change fork 3 bottom left (3).- Guide bar (4).- Gear selector (5).- Guide pin (6).

Roll the guide bar on a flat surface. .

Warping => Replace

WARNINGDO NOT TRY AND STRAIGHTEN A WARPED BAR.

INSPECTING THE ACTIONING ROD

INSPECTION OF THE FORKS AND GEAR SELECTOR

63

4. Check:- Movement of the gear change forks (in the guide bar)

Irregular movement => Replace the fork and the bar.

N.B.IF THE GEAR CHANGE FORK AND THE TRANSMISSION SPROCKETS ARE FOUND TO BE DAMAGED, REPLACE THE SPROCKETS THAT ARE SIDE BY SIDE ALL TOGETHER.

5. Measure:- Warping of the shafts (drive and driven)

Use a support between points and a dial gauge for linear measurement (1).

Outside that specified => Replace the warped shaft.

6. Inspect:- Sprocket teeth

Blue colouring/grooves/wear => Replace.

- Sprocket claws

Rounded edges/cracks/pieces missing =>Replace.

7. Inspect:- Gear change shaft (1).

Damage/warping/wear => Replace.

- Return spring (gear change shaft) (2).

- Return spring (limiter rod) (3).

- Circlip (4).

Wear/damage => Replace.

64

CRANKCASES

1. Wash the casings well with petrol.

2. Clean well the seal-bearing surfaces and the casing contact surfaces.

3. Inspect:

- Crankcases

Cracks/damage => Replace

- Oil passages

Obstructions => Blow through the passages with com-pressed air.


1. Inspect:- Bearings

Clean and lubricate, then turn the inner ring by hand.Roughness => Replace

2. Inspect:- Retaining ringsDamage/wear => Replace.

LOCKING RINGS AND WASHERS

1. Inspect:- Locking rings- Washers

Damaged/loose/distorted => Replace.

CRANKCASES


65

VALVES, ROCKERS AND CAMSHAFTVALVES, ROCKERS AND CAMSHAFT

4

Complete crankshaft1

65

Connecting rodPinWasher

2

3WasherNut

10

Roller bearing7

1211

Roller bearingGudgeon pinCirclip

8

9

Piston

Set of rings

13 Bearing

17

Oil seal14

1918

Key

Straight keyTraction gear

1516

Oil seal

Collar

21

2322

BearingBearingStraight key

20 Balancer (Counterweight)

24 Balancer gear

66

CRANKSHAFT AND BALANCER SHAFT

1. Fit:- Crankcase separator

Crankcase separator: 00M12501261

2. Fit:- Crankshaft

N.B.HOLD THE CONNECTING ROD WITH ONE HAND WHI-LE TURNIING THE NUT ON THE SPECIAL TOOL WITH THE OTHER HAND. USE THE TOOL UNTIL YOU FEEL THE CRANKSHAFT FIT INTO THE BEARING.

ATTENTIONTO PREVENT SCRATCHING TO THE CRANKSHAFT AND TO HELP ITS FITTING, APPLY GREASE TO OIL SEAL EDGES AND ENGINE OIL TO THE BEARINGS.

3. Fit:- Rocker shaft.Always use new rubber rings.

4. Fit:- Neutral switch

CRANKSHAFT AND BALANCER SHAFT

67

TRANSMISSIONTRANSMISSION

4

Primary shaft1

65

5th gear pinion6th gear pinionWasher

2

32nd gear pinion3rd gear pinion

10

Circlip7

1211

Secondary shaft1st gear cogwheel

2nd gear cogwheel

89

BearingRoller bearing

13 3rd gear cogwheel4th gear cogwheel14

1516

5th gear cogwheel

6th gear cogwheel

28

Collar25

3029

NutPlateBolt

26

27Ring gearWasher

19

2120

WasherCirclipWasher

17

18

Flat washer

Round spring clip

22 BearingBearing23

24 Oil seal

68

GEAR SELECTORGEAR SELECTOR

4

Selector drum1

65

StudGear change fork 1Gear change fork 2

2

3Stop leverSpring

10

Gear change fork 37

Round spring clip

89

Gear change fork 1 guide leverGear change fork 2 guide lever

69

1. Fit:- Primary and secondary transmission shafts (driving and driven).- Bottom left gear change fork (1).- Centre right gear change fork (2).- Top left gear change fork (3).- Guide bar (1) (short) (4).- Guide bar (2) (long) (5).

N.B.FIT THE GEAR CHANGE FORKS WITH THE ENGRAVED MARK UPWARDS AND IN ORDER (1,2,3,)

6. Check:- Gear selector operation

Irregular operation => Adjust.

N.B.CHECK THAT TRANSMISSION AND FORK OPERATION IS NORMAL BY TURNING THE GEAR CHANGE SELECTOR BY HAND.

CRANKCASE (LEFT HAND SIDE)

1. Apply:- Adhesive(to the crankcase contact surfaces).

N.B.DO NOT ALLOW SILICON TO COME INTO CONTACT WITH THE OIL PASSAGES.

2. Fit:- Guide pins.

3. Fit:- Crankcase (right) (onto left crankcase).

N.B.TAP THE CRANKCASE COVER LIGHTLY WITH A PLASTIC HA-MMER.

CRANKCASE (LEFT HAND SIDE)

70

4. Tighten:- Bolts (crankcase cover)

Bolts (casing): 1,0 Kgf.m (10 N.m)

5. Apply:- 2-stroke engine oil.(to the crankshaft elbow joints, bearings, oil feed holes).

6. Check:- Operation of the crankshaft and transmission.

Irregular operation => Repair.

71

GEAR CHANGE SHAFTG C G S

4

Complete selector shaft1

Torsion spring

23

BoltStop cam

72

1. Fit:- Torsion spring (1).- Positioning cam (2)- Bolt

N.B.SECURE THE SPRING TO THE STOP CAM AND ENSURE THE LATTER IS IN THE CORRECT POSITION,THEN TIGHTEN THE SECURING BOLT TO THE SPECIFIED TORQUE.

Bolt (limiter rod): 14 N.m (1.4 kgf.m)

2. Fit:- Gear change shaft assembly (3).

N.B.APPLY GREASE TO THE RETAINING RING PINS FIT THE ENDS OF THE SPRING INTO THE LIMITER (4).

73

CLUTCH AND CLUTCH BELL HOUSING C U C C U C OUS G

4

1

65

2

3

10

7

1211

89

1314

1516

28

2526

27

19

2120

17

18

2223

24

Clutch bell housingClutch housing Clutch plate WasherPressure plateSpringBolt with washer Friction diskFriction diskSpringPrimary traction gearWasherNutWasherFlat washerWasherNutSeparatorPush rod 1WasherNutSpherePush rod 2Complete push cam

SpringFlat washerOil sealRoller bearing

74

INSTALLING THE CLUTCH BELL HOUSING

1. Fit:- Balancing gear- Primary gear- Clutch bell housing

N.B.TAKE CARE TO FIT THE BALANCING GEAR AND THE PRI-MARY GEAR WITH THE CENTRING MARKS LINED UP.

FITTING THE CLUTCH

1. Fit:- Clutch bell casing (1).- Pressure washer (2).- Clutch housing (3).- Tab washer (4).- Clutch housing nut (5).

2. Tighten:- Clutch housing nut.

N.B.TIGHTEN THE CLUTCH HOUSING NUT WHILE HOLDING THE HOUSING WITH THE UNIVERSAL CLUTCH HOLDER .

Clutch holder: 00M12501260

Clutch housing nut: 70 N.m (7.0 kgf.m)

3. Fold:- Edge of tab washer (1).(upwards onto a flat side of the nut)

INSTALLING THE CLUTCH BELL HOUSING

FITTING THE CLUTCH

75

4. Fit:- Friction disks (1).- Separators (2).

N.B.- FIT THE DISKS AND SEPARATORS ALTERNATELY INTO THE CLUTCH ASSEMBLY, STARTING WITH A FRICTION DISK AND

ENDING WITH A FRICTION DISK AS WELL.

- LUBRICATE ALL THE DISKS AND SEPARATORS WITH ENGI-NE OIL BEFORE FITTING.

- BE SURE TO FIT EACH SEPARATOR WITH ITS PROJECTIONS TURNED AT 90 TO THE PREVIOUS ONE. CONTINUE WITH THIS PROCEDURE IN A CLOCKWISE DIRECTION UNTIL ALL THE SEPARATORS HAVE BEEN INSTALLED.

5. Fit:- Activating rod.- Ball.

6. Fit:- Pressure plate (1).- Compression springs (2).- Bolts (3).

Bolts (clutch spring): 0,6 Kgf.m (6 N.m)

N.B.TIGHTEN THE SPRING BOLTS GRADUALLY AND IN A DIA-GONAL FASHION.

7. Check:- Position of the activating plate.

Push the lever assembly in the direction of the arrow and ensure that the alignment marks line up.

76

9. Adjust:- Position of the activating plate.

Adjustment steps:- Loosen lock nut (1).

- Turn the adjuster (2) clockwise or anticlockwise to line up the marks.

- Hold the adjuster to stop it from moving and tighten the locknut.

ATTENTIONBE CAREFUL NOT TO OVERTIGHTEN THE ADJUSTER (2) AND ELIMINATE THE CLEARANCE BETWEEN THE TWO AC-TIVATING RODS.

- Tighten the lock nut (1).

Lock nut: 10 N.m (1kgf.m)

10. Fit:- Guide pins.- Crankcase gasket- Right hand crankcase cover

Crankcase cover bolts: 8 N.m (8kgf.m)

77

MAGNETO AND STARTER SYSTEMSG O S S S S

4

1

65

2

3

10

7

1211

89

1314

1516

19

17

18

Magneto flywheel supportBoltStarter wheelRoller bearingIntermediate starter gear shaftFlat washerIntermediate starter gearIntermediate starter gear plateBoltStarter clutchStarter clutch spring coverPinSpringBoltMagnetoStatorNutFlat washerBolt

78

INSPECTING THE STARTER GEAR

1. Inspect:- Starter system gear teeth (a) (b) (c).

Rough edges/swarfing/roughness/wear => Replace.

2. Check:- Operation of the starter clutch.

Push the guide pins in the direction of the arrow.

Non-smooth functioning => Replace.

Checking steps:- Hold the starter clutch.

- On turning the (big) starter gear clockwise (A), the starter clutch and the starter gear should be coupled.

- If not, the starter clutch is damaged.Replace.

- On turning the starter gear in an anticlockwise direction (b), it should turn freely.

- If not, the starter clutch is damaged.Replace.

MAGNETO AND STARTER GEAR

1. Fit:- Intermediate starter gear- Securing plate

2. Apply:- 2-stroke engine oil. (to the starter gears).

3. Fit:- Starter clutch support plate- Roller bearing- Starter gear.

4. Fit:- Key.- Magneto rotor.

INSPECTING THE STARTER GEAR

79

N.B.FIT THE ROTOR PROVISIONALLY, ALIGNING THE KEYWAY WITH THE KEY. TURN THE STARTER GEAR CLOCKWISE AND FIT THE ROTOR ONTO THE STARTER GEAR.

5. Tighten:- Nut (magneto flywheel).

Magneto flywheel nut: 80 N.m (8kgf.m)

N.B.TIGHTEN THE NUT (1) WHILE HOLDING THE FLYWHEEL (2) WITH THE ROTOR HOLDER (3).

TAKE CARE NOT TO ALLOW THE ROTOR HOLDER TO TOUCH THE ROTOR PROTRUSIONS.

6. Fit:- Guide pins.- Crankcase cover gasket.- Left hand crankcase cover

Crankcase cover bolts: 5 N.m (5kgf.m)

80

CYLINDER, PISTON, CYLINDER HEAD AND EXHAUST VALVEC , S O , C US

4

1

65

2

3

10

7

1211

89

1314

1516

19

2120

17

18

2223

24

Cylinder headStudNutFlat washerSpark plugHead gasketCylinderCylinder gasketClutch cable securing plateStudStudPinNutExhaust valveRight hand exhaust valve coverBoltExhaust valve gasketOil sealSEEGER RingClutch valve activation supportBoltLeft hand exhaust valve cover.BoltExhaust valve pulley

28

25

3029

26

27

34

313233

BoltWasherWasherExhaust valve front cableExhaust valve rear cableStudSet of piston ringsCirclipPistonGudgeon pin

81

FITTING PISTON RINGS, PISTON AND CYLINDER

1. Fit according to the following sequence:- Secondary ring (scraper) (1).- Top ring (compression) (2).

N.B.- LUBRICATE THE PISTON AND THE RINGS WELL WITH EN-GINE OIL.

2. Fit:- Piston- Connecting rod big end needle bearings- Gudgeon pin- Circlip

N.B.- APPLY ENGINE OIL TO THE GUDGEON PIN.

- THE ARROW ON THE PISTON SHOULD BE TOWARDS THE EXHAUST SIDE.

- BEFORE FITTING THE CIRCLIP, COVER THE CRANKCASE OPENING WITH A CLEAN CLOTH.

3. Fit: Guide pins (1). Cylinder gasket.

FITTING PISTON RINGS, PISTON AND CYLINDER

82

4. Lubricate:- External surface of the piston- Rings- Inner surface of the cylinder

5. Fit:- Cylinder (1).

N.B.- FIT THE CYLINDER WITH ONE HAND WHILE COMPRES-SING THE RINGS WITH THE OTHER.

FITTING THE CYLINDER HEAD

1. Fit:- Cylinder head gasket

2. Fit:- Cylinder head- Nut with washer

Cylinder head nuts tightening torque: 22 N.m (2,2 kgf.m)

N.B.- APPLY ENGINE OIL TO THE BOLT THREADS.

FITTING THE CYLINDER HEAD

83

FITTING THE REED VALVE

N.B.BEFORE FITTING, CHECK THAT THERE ARE NO CRACKS, DISTORTIONS OR BREAKAGES ON THE REED PETALS. IF THERE ARE, THEY MUST BE REPLACED IN THE FOLLOWING WAY:

- REMOVE THE SECURING SCREWS FROM THE HEIGHT LIMITER AND FROM THE INLET VALVE PETALS.

- CHECK THAT THERE ARE NO CRACKS IN THE PETALS SECURING BASE. IF THERE ARE, RENEW THE REEDS.

To refit the reed valve, proceed in the reverse order to dis-mantling, paying special attention to the correct positioning of the height limiter and the reed (with the bevels matching). The elimination of the height limiter and the type of reed used will modify the performance of the engine and may make it less reliable. Check the reed cage O- ring and replace it if damaged.

Valve thickness: 0.5 mm.

Height of the stop plate: 8.8 mm.

Valve flexing limit: 0.5 mm.

FITTING THE REED VALVE

84

3. Fit:- Spark plug

Spark plug: 20 N.m (2.0 kgf.m)

14. Fit:- Oil drain plug- Fill with 800 c.c. of SAE 10W30 oil through the plug hole located on the right hand crankcase cover.

Oil drain plug: 15 N.m (1.5 kgf.m)

REFITTING THE ENGINE INTO THE FRAME

1. Dismantle side covers.

2. Remove the petrol tank.

3. Remove the exhaust pipe.

4. Dismantling the carburettor.

- Remove filter box-carburettor pipe (secured with a jubilee clip).

- Loosen jubilee clip on carburettor pipe to cylinder.

- Remove carburettor.

- Remove jubilee clip and pipe from cylinder head to carbu-rettor.

5. Removing the gear change lever.- Remove bolt (1).

- Remove change backlash bush (2).

6. Removing the chain.- Remove chain coupling link clip

G G O

85

7. Extracting the radiator.- Drain the cooling system.

Remove system inlet (1) and outlet (2) hoses and tank hose (3).

Remove radiator.

86

8. Extracting the oil pump cable.- Remove cover.

Remove the retaining circlip with pulley and torsion recovery spring

Extract cables and remove them from the engine.

9. Extracting the oil tank to engine hose.- Remove the tank hose and plug it.

- Plug the oil tank outlet.

10. Removing the clutch operating cable.- Free the clutch cable from the handlebars.- Remove the the tensioning cable from the crankcase.- Remove the clutch operating cable.

11. Freeing the exhaust valve operating cable.- Remove cover (1).

- Loosen cable by screwing in, and extract it from the pulley.- Unscrew the two tensioners and remove the cables.

87

12. Removing electrical connections.- Remove spark plug connector.- Remove the temperature meter cable.- Remove the magneto cable.- Remove earth cable from right hand side of the crankcase.- Remove neutral earth cable.- Remove starter motor power supply cable.- Remove cables from the coil.

13. Removing the engine cradle.- Remove the UNEX clamps.

- Remove the 6 bolts securing the cradle to the engine and to the chassis.

- Withdraw the engine cradle from below the machine.

14. Extracting the engine.- Remove the swinging arm shaft without extracting it com-pletely, ensuring that it only joins the swinging arm and the chassis.

- Insert a support shaft into the other side joining only the swinging arm and chassis, to ensure that the swinging arm and chassis do not come loose.

- Unfasten the engine from the top bracket.

- Remove the engine.

N.B.IT IS ADVISABLE TO PLACE A SUPPORT UNDER THE ENGI-NE BEFORE FREEING IT FROM THE CHASSIS, TO AID IN THE DISMANTLING PROCESS.

88

CARBURETTORC U O

4

1

65

2

3

10

7

1211

89

1314

1516

19

2120

17

18

2223

24

Air screw assemblyIdler jetMain jetWasherSpraySpray needlePinBoltNeedle valveIdler screw assemblySpringSealBoltWasherThrottle valvePipeTube clipBreather tubeDrain screwBreather tubeFloatRingSheathCable adjusting nut

28

25

29

26

27

WasherFilterCoverClipDrain pipe

89

DISMANTLING

1. Extract:- Riders seat.- Fairing.- Fuel tank.- Air filter canister.

See SEAT, SIDE COVERS AND FUEL TANK section in CHAPTER 3.

2. Drain:- Fuel (carburettor bowl).

N.B.PLACE A CLOTH UNDER THE FUEL DRAIN PIPE TO ABSORB SPILT FUEL.

WARNINGPETROL IS HIGHLY INFLAMMABLE. AVOID SPILLINGPETROL ON TO A HOT ENGINE.

3. Disconnect:- Breather pipe.- Fuel pipe.- Drain hose.

4. Loosen:- Pipe clamp screws.- Bolt (air filter canister).

N.B.PULL THE MANIFOLD CLAMP BACKWARDS

- Extract the rubber seal between the carburettor and the filter cansiter.

- Pull the carburettor backwards.

5. Extract:- Throttle cable.

Remove the carburettor cover together with the closing val-ve.

- Choke cable.

Remove the choke together with the spring.- Completely drain the antifreeze.

- Extract the heating hoses from the carburettor.

DISMANTLING

90

DISMANTLING

N.B.THE PARTS BELOW CAN BE CLEANED AND INSPECTED WITHOUT DISMANTLING THE CARBURETTOR. (ALL THE INTERNAL PARTS, EXCEPT THE CHOKE, CAN BE CLEANED AND INSPECTED WITHOUT DISMANTLING THE CARBU-RETTOR).

- CLOSING VALVE

- CLOSING VALVE NEEDLE

1. Extract:- Complete carburettor.

2. Extract:- Throttle cable

N.B.COMPRESS THE GAS VALVE RETURN SPRING AGAINST THE COVER AND EXTRACT THE THROTTLE CABLE TERMINAL THROUGH THE GAS VALVE CHANNEL.

3. Extract:- Cold start (choke) valve puller bracket.

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91

4. Extract:- Low speed circuit air quantity regulator (compensator) screw.- Spring- Washer- O-ring

5. Extract:- Carburettor bolts and bowl.

N.B.THIS ENABLES ACCESS TO THE MAXIMUM, MINIMUM AND COLD START BORES, AS WELL AS THE FLOAT AND ITS NEE-DLE VALVE.

Compensator screw: de vuelta.

INSPECTION

1. Clean:- All the components of the carburettor with solvent (take care not to damage the carburettor bowl gasket or the cold start valve O-ring).

2. Blow:- Through all the air, oil and petrol passages with compressed air.

3. Check:- the weight of the float- engraved on it (14 grams) with scales. = > If it exceeds this weight, renew it.

- the needle controlling entry of petrol into the bowl, toge-ther with its float connecting stem spring. => If its condition is not correct, renew it.

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92

I The condition of the cold start system piston valve. => In the event of the vulcanised closing seat or the metal body of the piston being damaged (scratches and/or corrosion that exceed 25% of its total area).

- Size of the bores based on the numbers etched onto them. => If they are not in agreement with that specified, replace them with suitable ones. Failure to do so may result in the performance of the engine being affected.

- The position of the tapered dosing needle. It should be located in the centre slot of the three available.

N.B.MOVING THE CIRCLIP ON THE NEEDLE UPWARDS RESULTS IN A LEANER MIXTURE, AND MOVING IT DOWNWARDS RE-SULTS IN A RICHER MIXTURE. THIS ALLOWS ADJUSTMENTS TO BE MADE FOR EXTREME CLIMATIC CONDITIONS.

- THE CONDITION OF THE TAPERED DOSING NEEDLE. => IF THERE IS DAMAGE VISIBLE ON ITS CIRCUMFERENCE, CHANGE IT

93

- The absence of scratches on the minimum circuit air regu-lator screw cone. These would affect its performance.

- The absence of scratches on the sliding valve. => In the event of these exceeding 25% of its total area, renew it.

N.B.BE SURE TO FIT A VALVE WITH THE SAME CHARACTERISIT-CS (SEE MARKINGS ON ITS BASE).

REFITTING

This is a reversal of the REMOVAL procedure.

Take care with the following points:

1. Fit:- Spring (closing valve).- Closing valve assemblyWith the carburettor cover and throttle cable.

- Spring (choke).- Choke assembly.With the choke and choke cable.

2. Fit:- Carburettor.

3. Tighten:- Clip (air filter box).- Clamp screws.

4. Connect:- Drain hose.- Breather pipe.- Fuel pipe.

G

94

5. Adjust:- Idle speed

See the MEASURING AND ADJUSTING IDLE SPEED section in CHAPTER 3.

6. Adjust:- Throttle cable play.

See the ADJUSTING THE THROTTLE CABLE section in CHAPTER 3.

ADJUSTING THE FUEL LEVEL

1.Measure:- Fuel level (a).


Fuel level: 1.5 2.5 mm below the bowl line

Adjustment steps:- Place the motorcycle on a flat surface.

- Place a jack or a support under the engine to ensure that the carburettor is positioned vertically.- Connect the fuel level meter (1) to the drain pipe (2).

- Loosen the drain screw (3).

- Hold the meter vertically and close to the line of the car-burettor bowl.

- Measure the fuel level (a) with the meter.

- If the level is incorrect, adjust it.

- Remove the carburettor.

- Inspect the valve seat and needle valve.

- If these parts are worn, replace both.

- If they are normal, adjust the float level by bending slight-ly the edge (4) of the float.

Float height: 15.5 - 16.5 mm

- Fit the carburettor.

- Check the fuel level once again.

JUS G U

95

FRONT WHEEL DIAGRAMO G

4

1

65

2

3

10

7

1211

89

1314

15

16

19

20

1718

Front 110/80 tyreFront wheel assy.Front wheel axleDisk side bushFlat washerWheel axle head nutAxle nut protectorBearing 6202Front wheel bearing separator sub-assembly300 mm front disk brakeBrake disk securing boltFront brake calliperM10 bolt Front brake padFront brake pad securing springCalliper bleeding assemblyM31 radial calliper coverM34 radial calliper cover

Bleed nipple

Bleed nipple

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DISMANTLING

WARNING- ENSURE THAT THE MOTORCYCLE IS SUPPORTED FIRMLY AND THERE IS NO RISK OF IT FALLING.

- PLACE THE MOTORCYCLE ON A FLAT SURFACE.

1. Extract:- Front brake calliper (Bolts 1 and 2).

2. Extract:- Nut protecting cover.- Nut (left side).

3. Raise:- Front wheel(Put a suitable support under the engine).

4. Extract:- Front wheel axle.- Front brake disk assembly.- Dustguard/spacer.- Front wheel.

INSPECTING THE FRONT WHEEL

1. Inspect:- Front wheel axle. (By rolling it on a flat surface).

Warping => Replace.

WARNINGDO NOT TRY STRAIGHTENING A WARPED AXLE.

Wheel axle warp limit: 0,25 mm

2. Inspect:- Neumtico delantero.


DISMANTLING

INSPECTING THE FRONT WHEEL

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See the INSPECTING THE TYRES section in CHAPTER 3.- Front wheel

See the INSPECTING THE WHEELS section in CHAPTER 3.

3. Check:- Spokes.

Warps/damage => Replace.

5. Measure:- Distortion of the front wheel

Above that specified => Replace.

Distortion limits for the front wheel:Radial (a): 0,5 mm

Lateral (b): 0,8 mm

6. Check:- Front wheel bearings.

Bearings allow play in the wheel hub or the wheel does not turn freely => Replace.

- Retaining rings.


7. Inspect:- Spacer.

With scratches/worn => Replace the spacer and the retaining ring.

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INSPECTING THE SPEEDOMETER

This speedometer is fitted with a Hall Effect sensor. As this is a precision magnetic device, it should not be dismantled. In the event of it becoming faulty, the unit must be renewed.

DISMANTLING THE FRONT DISK CALLIPER

- Loosen the banjo bolt (1) from the bottom end of the brake pipe and tighten it slightly.

- Unscrew the calliper mounting bolts (2) and separate the calliper (3) backwards from the disk.

PRECAUTIONCLEAN OFF ANY SPILT BRAKE FLUID REMAINS IMMEDIA-TELY.

Fitting the front calliper:- Fit the bottom end of the brake pipe and the calliper.- Tighten to nominal torque.

Calliper mounting bolts: 35 40 N.m (3,5 4 kgf.m)

- Tighten the brake banjo bolt.

- Check brake fluid level.

- Bleed the brake system pipe (consult Bleeding the brake system pipe in this chapter).

- Check the condition of the braking force to see if any resistance is noted or any loss of fluid.

WARNINGDO NOT ATTEMPT TO RIDE THE MOTORCYCLE UNTIL THE BRAKE LEVER IS OPERATING PROPERLY. PUMP THE LEVER UNTIL THE PADS ARE AGAINST THE DISK. IF NOT, THE BRAKES WILL NOT WORK THE FIRST TIME THE LEVER IS USED.

INSPECTING THE SPEEDOMETER

DISMANTLING THE FRONT DISK CALLIPER

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Extracting the front brake pads.- Remove the front brake calliper (see Dismantling the front brake calliper in this chapter).

Extract:- Pad springs (1).- Pin.- Brake pads (2).

Fitting the front brake pads- Press the calliper pistons in manually.- Fit the pads inside the calliper.- Adjust the pad springs.

WARNINGDO NOT ATTEMPT TO RIDE THE MOTORCYCLE UNTIL THE BRAKE LEVER IS OPERATING FULLY. THIS IS ACHIEVED BY PUMPING THE LEVER UNTIL THE PADS ARE AGAINST THE DISK. IF NOT, THE BRAKES WILL NOT WORK THE FIRST TIME THE LEVER IS USED.

Inspecting the pads for wear- Remove the front brake pads.

- Examine both brake pads.If the wear has caused the wear indicating groove (1) to di-sappear, both pads must be renewed.

Extracting the front brake cylinder.- Extract the bolt (1) and remove the flexible pipe from the brake cylinder reservoir.

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N.B.THE MASTER CYLINDER (1) IS INCORPORATED INTO THE FRONT BRAKE LEVER ASSEMBLY.

- EXTRACT THE SCREWS (2) AND THE FRONT BRAKE LEVER ASSEMBLY.

PRECAUTIONCLEAN OFF ANY SPILT BRAKE FLUID REMAINS IMMEDIA-TELY.

Extract:- Brake lever mounting bolt and nut.- Brake lever.

Fitting the front master cylinder:- Fit the brake lever assembly and tighten the securing screw.

- Tighten the flexible brake pipe bolt.

- Bleed the brake system pipe (consult Bleeding the brake system pipe in this chapter).

- Check the condition of the braking force to see if any resis-tance is noted or any loss of fluid.Checking the brake lever master cylinder (visual check):

- Extract the master cylinder (consult Extracting the front master cylinder in this section).

- Dismantle the front master cylinder:

- Check that there are no scratches, corrosion or holes on the inner walls of the master cylinders and on the outer part of each piston.

- If any damage is discovered on the master cylinder or on the pistons, change them.

- Examine the primary seal and secondary seal.

- If the seal is worn, soft (perished) or swollen, change the piston assembly to renew the seals.

- If fluid loss is noticed at the brake lever, change the seals.

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Checking the brake calliper main cylinder:- Check that the anti-dust boots are not damaged.If they are, change them.

- Check that the piston return is not damaged. If it is, renew it.

- Check that the relief port and feed port are not blocked.if the relief port is blocked, the brake pads will bind on the disk. Inject compressed air to clean the ports.

Extracting the brake disk:- Remove the front wheel.

- Unscrew the mounting bolts and extract the disk.

Fitting the brake disk- Fit the brake disk onto the front wheel so that side (2) faces outwards.

- Apply a temporary blocking device to the threads of the brake disk mounting bolts(1).

- Tighten the front brake disk mounting bolts(1).

Nominal tightening torque: 1,0 ~ 1,2 Kgf.m (10 ~ 12 N.m)

Wear to the brake disk:- Measure the thickness of the disks (A) at the point where they are most worn.

- If the disk is more worn than specified in the service limit, renew it.

Measurement area (B).

Standard thickness of the front brake disk. 3,8 4,1 mm

Service limit: 3,50 mm

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Brake disk distortion:- Raise the motorcycle on the jack so that the tyre is clear of the ground.

- To check the front disk, turn the handlebars completely to one side.

- Place a dial calibrator against the disk (A) as shown, and measure the disks deviation from centre as the tyre is turned by hand (B).

- If the deviation from centre exceeds the service limit, renew the disk.

Disk deviation from centre: Standard: less than 0.15mm Service limit: 0,3 mm

Bleeding the brake system pipeThe brake fluid has a very low compression coefficient, with the result that almost all the movements of the brake lever are transmitted directly to the calliper for braking. Air however compresses easily. When air enters the brake system pipes, the movement of the brake lever is partially used up in com-pressing the air. This causes the lever to feel spongy and leads to a loss of braking power.

WARNINGBE SURE TO BLEED AIR OUT OF THE BRAKE SYSTEM WHEN THE BRAKE LEVER FEELS SPONGY AFTER CHANGING THE BRAKE FLUID OR WHEN THE BRAKE SYSTEM PIPE HAS BEEN LOOSENED FOR ANY REASON.

Extract:- Bolts (1).

- Reservoir cap (2).

- Fill the reservoir with brake fluid up to the top reservoir line.

- With the cap removed, pump the brake lever slowly several times until no bubbles can be seen rising through the liquid.

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Purge the air completely from the master cylinder using this procedure.- Remove the transparent plastic cap from the bleed nipple and place the other end of the pipe in a container.

- Repeat the following procedure until there is no air left emerging from the plastic pipe:

- Pump the brake lever unti

Derbi GPR 125 R

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